It is an interconnected automation system developed by the Swiss company

GHS Automation AG (Schwarzenburg, Switzerland), represented in Spain by Alboex, has created a line of automation for the also Swiss Weidmann Plastics Technology AG Within the cell production, the company has a molding machine by injection to make trims strips for front and rear doors of the car. GHS, fully responsible for all automation equipment, has created a system that allows to carry out the following tasks: precise insertion of two metal strips, to the left and right side; extraction of the castings of the cavity; and placement of the pieces finished conveyor belts.

The complete automation of the processes is the key to achieve the production of plastic parts in countries with high wage costs to be profitable. And to achieve this is not enough with the mere installation of efficient molding machines injection: to achieve uninterrupted use of the machines, 24 hours a day 7 days a week, is necessary that the supply of material and the removal of the finished parts are also continuous. Thus, manipulation and movement of material and parts operations are essential to the production process.

The discerning demands of producers and suppliers of plastic parts are based on seemingly simple but essential aspects: increased performance, greater flexibility, greater security and higher quality. For manufacturers of injection moulding machines and automation equipment, these complex requirements are a huge, which involves much more than measures challenge for the "reduction of non-productive periods". If the periods of maximum production and postproduction are those that determine the length of the cycle and ejection times, then the process must integrate as many functions as possible and reasonable.

At the same time, this requires the simultaneous operation of all units involved in the production process, condition that can only be granted through an interconnected system of automation.

The discerning demands of producers and suppliers of plastic parts are based on seemingly simple but essential aspects: increased performance, greater flexibility, greater security and higher quality

This situation leads us to ask ourselves who must rely on the design and implementation of this complex system of automation and production. Therefore, in most cases, this task is not to manufacturers of machines, but for systems integrators creative that, in these complex projects, assume the role of main contractors.

In this sense, the perfect integrated solutions provider is one that, in addition to providing the necessary components, account with the appropriate knowledge and experience of many years in development, design and integration of handling equipment.

GHS Automation AG, a company which has been making handling for molding equipment by injection and other plastic parts for more than 25 years, is a perfect example. The need of the customers integrate increasingly more functions in the process of molding injection has led to GHS to create integrated automation solutions, for which is based on two factors: one, design from the own company handling equipmentvery standardized; two comprehensive selection of high quality in the market.

A competent provider of systems solutions should know all the processes of manufacture of pieces of plastic and the high level of integration required. Therefore, the team of specialists of GHS was chosen to create the system of automation of a line of moulding by injection, used to produce high-quality car doors trims slats. The project is commissioned by Weidmann Plastics Technology, supplier of parts for the automotive sector, working for a German manufacturer of high class vehicles. Trims slats are placed in the rear and front doors of a specific car model.

Variants for the left and right side are manufactured simultaneously in a machine of molding by injection of two components. Each of the pieces is a metal band from reinforcement, which should be inserted with great accuracy in a mold of injection multicavidad before starting the process of molding by injection. There are two variants of the slats (long and short version), both the mould and handling of the pieces/slats trims system must present an enormous flexibility and to accommodate rapid changes. The client instructed Krauss-Maffei molding machine by injection of high-performance KM575/650, GHS was selected to design and implement most of the automation of the line equipment.

Automation equipment performs the following tasks: inclusion of slats of metal, extraction of the castings and placement of the pieces finished conveyor belts

The system consists of: car ladder for eight trays of bands, which are loaded with 30 decorative bands; a unit of loading and unloading; a two-axis handling equipment; a pneumatic gripper and positioning unit (pick and place); a Kuka six axis robot with a grip multifunction device; and a conveyor belt of two flats which are deposited the finished parts to get them off of the cell.

The system is capable of simultaneously handling a total of 16 trays with metal bands left and right and ensures continuous of the finished parts positioning and extraction

First of all, a total of 30 decorative bands is placed on trays.

Each cart ladder are loaded eight trays, each with decorative bands for the left and right side. Then the car enters manually loading and unloading unit alternate. The two-axis handling equipment takes the upper tray and her oriented so that it passes to the pneumatic gripper and positioning unit. Grip and positioning unit removed the slats of trays in a synchronized move and transferred metal strips to a focused unit. The system of multifunctional grip, which is mounted on top of the six-axis robot, takes the metal bands and moved them from the unit of charge to the injection mold. At the end of the cycle of injection molding, which is carried out at a time to the process described above, the grip of the robot system out of half of the mold removal the finished piece and the drinking system (the system performs this task by hoisting)(, suction and pressure) and placed a new bands in the fixed half of the mold. During the next injection moulding cycle, the robot and gripper system returning to the unit of charge to place trims slats on the conveyor and take new metal bands.

The removal of the finished pieces of cast two cavities is carried out in just six seconds, thanks to which the system has time to spare for the rest of the tasks described above during the injection cyclelasting 80 seconds.

The system is capable of simultaneously handling a total of 16 trays with metal bands left and right and guarantee a positioning and extraction continued of the finished parts. Thus equipped with this system, the injection molding equipment is capable of producing high quality parts in an autonomous process, without the intervention of any person, for about six hours. Change of ladder trucks nor generates any idle time, because a car is replaced by another completely filled while the system is downloading the last tray. On the other hand, used modules have been tested, which guarantees a high degree of security within this continuum of multiple movements. In addition, the use (mostly) of components and separate units of standardized control facilitates operations of control, maintenance, service and spare parts management. The team of engineers from GHS has succeeded in creating a very compact line, a relatively small space and that it can be accessed freely.

The team is covered by a guarantee of 18 months (unlimited number of operating hours). By choosing to GHS as a main supplier, Weidmann has guaranteed the fulfilment of all requirements for delivery and performance provided by the supplier and customer alike.

The removal of the finished pieces of cast two cavities is carried out in just six seconds, thanks to which the system has time to spare for the rest of the tasks described above during the injection cyclelasting 80 seconds